Vehicle pedal assembly with hysteresis assembly

ABSTRACT

A vehicle pedal assembly with a rotatable pedal. A hysteresis assembly includes a friction device and plunger, and first and second springs that are all separate and decoupled from each other and the pedal. The first spring exerts a force against the friction plunger that forces the friction device into frictional contact with the housing to generate and transfer a resistance force to the pedal. The first spring also exerts a force against the pedal when a foot force is removed from the pedal to return the pedal to idle with and without the movement of the friction device and without the force of the second spring. The second spring exerts a force against the friction device when the foot force is removed to return the pedal to idle without the force of the first spring. Barriers block the entry of debris into the housing.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the filing date and disclosure ofU.S. Provisional Application Ser. No. 61/544,871 filed on Oct. 7, 2011and U.S. Provisional Application Ser. No. 61/604,361 filed on Feb. 28,2012, which are explicitly incorporated herein by reference as are allreferences cited therein.

FIELD OF THE INVENTION

The present invention relates generally to a pedal mechanism, and inparticular, to a vehicle accelerator pedal assembly with a hysteresisassembly.

BACKGROUND OF THE INVENTION

Automobile accelerator pedals have, in the past, been linked to enginefuel subsystems by a cable, generally referred to as a Bowden cable.While such accelerator pedal designs varied, the typical return springand cable friction together created a common and accepted tactileresponse for automobile drivers. For example, friction between theBowden cable and its protective sheath reduced the foot pressurerequired from the driver to hold a given throttle position. Likewise,friction prevented road bumps felt by the driver from immediatelyaffecting throttle position.

The mechanical cable-driven throttle systems, however, have beenreplaced with a more fully electronic, sensor-driven approach. With thefully electronic approach, the position of the accelerator pedal is readwith a position sensor and a corresponding position signal is madeavailable for throttle control. The sensor-based approach has beenespecially compatible with electronic control systems in whichaccelerator pedal position is one of the several variables used forengine control.

Although such drive-by-wire configurations have been technicallypractical, drivers have generally preferred the feel, i.e., the tactileresponse, of the conventional cable-driven throttle systems. Designershave attempted to address this preference withhysteresis/friction-generating mechanisms or modules in the electronicpedal assemblies which emulate the tactile response of cable-drivenaccelerator pedals.

In this regard, there continues to be a need for a simpler, morecost-effective, and more reliable vehicle pedal assembly with ahysteresis/friction-generating assembly.

SUMMARY OF THE INVENTION

The present invention is generally directed to a vehicle pedal assemblywhich comprises a pedal housing; a pedal extending into the pedalhousing, the pedal being mounted to the pedal housing for rotationrelative to the pedal housing; and a pedal hysteresis assembly in thepedal housing including a friction device adapted for movement in thepedal housing, a friction plunger adapted to exert a force against thefriction device, a first spring extending between the pedal and thefriction plunger and adapted to exert a spring force against thefriction plunger which causes the friction plunger to exert the forceagainst the friction device which causes the friction device intoabutting frictional contact with the pedal housing in response to therotation of the pedal to generate and transfer a resistance force to thepedal; a lever arm extending from the pedal into contact with thefriction device and adapted to move the friction device in a firstdirection in response to the rotation of the pedal; and a second springin contact with the friction device and adapted to exert a spring forceagainst and move the friction device in a second direction opposite thefirst direction.

In one embodiment, the pedal housing defines a channel and the frictionplunger is adapted to move in the channel.

In one embodiment, the friction plunger includes an elongate baseextending in the channel and opposed plunger plates adapted to abutagainst the first spring and the friction device respectively.

In one embodiment, the friction device includes a base abutted againstan interior surface of the pedal housing and a wall, the second springand the lever arm abutting against the wall of the friction device.

In one embodiment, the wall of the friction device extends between thesecond spring and the lever arm.

In one embodiment, the first end of the pedal includes a drum defining ashoulder, the first spring extending between the shoulder on the drumand the friction plunger.

In one embodiment, the pedal housing defines a front opening andincludes a back wall, the pedal extending through the front opening, andthe friction device being adapted for frictional contact with the backwall of the housing.

The present invention is also directed to a vehicle pedal assembly thatcomprises a pedal housing, a pedal extending into the pedal housing andadapted for rotation relative to the pedal housing from an idle positionin response to the application of a foot force against the pedal, apedal hysteresis assembly in the pedal housing including a frictiondevice that is separate from the pedal and adapted for movement in thepedal housing in response to the rotation of the pedal from the idleposition, and means for rotating and returning the pedal to its idleposition with and without the movement of the friction device.

In one embodiment, the means for rotating and returning the pedal to itsidle position with and without the movement of the friction devicecomprises a first spring between and separate from the pedal and thefriction device, the first spring generating a first compressive forcethat causes the friction device into abutting frictional contact withthe pedal housing in response to the rotation of the pedal forgenerating and transferring a resistance force to the pedal, the firstspring also being adapted to exert a second compressive force againstthe pedal in response to the removal of the foot force from the pedalthat returns the pedal to its idle position with and without themovement of the friction device.

In one embodiment, the pedal hysteresis assembly includes a frictionplunger that is separate from and extends between the first spring andthe friction device, the first spring being adapted to exert the firstspring compression force against the friction plunger which causes thefriction device into abutting frictional contact with the pedal housing.

In one embodiment, the pedal hysteresis assembly further includes meansfor rotating and returning the pedal to its idle position without thesecond compressive force of the first spring.

In one embodiment, the means for rotating and returning the pedal to itsidle position without the second compressive force of the first springcomprises a lever arm extending from the pedal into contact with thefriction device and a second spring extending between the pedal housingand the friction device, the second spring being adapted to exert acompressive spring force against the friction device in response to theremoval of the foot force from the pedal which causes the movement ofthe friction device, the rotation of the pedal lever arm, and the returnof the pedal to its idle position without the second compressive forceof the first spring.

In one embodiment, the first spring is adapted to rotate and return thepedal to its idle position without the compressive spring force of thesecond spring.

The present invention is further directed to a vehicle pedal assemblycomprising a pedal housing; a pedal extending into the pedal housing,the pedal being mounted to the pedal housing for rotation relative tothe pedal housing from an idle position in response to the applicationof a foot force against the pedal; and a pedal hysteresis assembly inthe pedal housing that includes a friction device that is separate fromthe pedal and adapted for movement in the pedal housing, a frictionplunger that is separate from the friction device and the pedal andadapted to exert a force against the friction device, a first springthat is separate from the pedal and the friction device and the frictionplunger and extends between the pedal and the friction plunger and isadapted to exert a first spring force against the friction plunger whichcauses the friction plunger to exert the force against the frictiondevice which causes the friction device into abutting frictional contactwith the pedal housing in response to the rotation of the pedal togenerate and transfer a resistance force to the pedal, the first springalso being adapted to exert a second spring force against the pedal inresponse to the removal of the foot force from the pedal that returnsthe pedal to its idle position with and without the movement of thefriction device, a lever arm extending from the pedal into contact withthe friction device and adapted to move the friction device in a firstdirection in response to the rotation of the pedal, and a second springin contact with the friction device and adapted to exert a spring forceagainst and move the friction device and the lever arm in response tothe removal of the foot force from the pedal that returns the pedal toits idle position without the second spring force of the first spring,the first spring further being adapted to exert the second spring forceagainst the pedal in response to the removal of the foot force from thepedal to return the pedal to its idle position without the spring forceof the second spring.

The present invention is still further directed to a vehicle pedalassembly comprising a pedal housing defining a front opening and aninterior cavity, a pedal including a pedal arm extending through thefront opening and a drum located in the interior cavity, and a firstdebris barrier defined at the front opening of the pedal housing.

In one embodiment, the first debris barrier includes respective opposedand adjacent extended shoulders formed on the pedal housing and thepedal drum.

In one embodiment, another first debris barrier is defined by anoutwardly projecting tab on a lower portion of the drum and is locatedopposite the front opening of the pedal housing.

In one embodiment, a second debris barrier is defined by at least afirst outwardly projecting ear formed on the drum of the pedal and islocated behind the first debris barrier.

In one embodiment, at least a first debris retention chamber is definedin the interior cavity of the pedal housing between the first and seconddebris barriers.

In one embodiment, the pedal housing includes a back wall and furthercomprises a pedal hysteresis assembly located in the interior cavity ofthe pedal housing between the drum and the back wall of the pedalhousing, the pedal hysteresis assembly includes a friction deviceadapted for sliding movement against the back wall of the pedal housing,a friction plunger adapted to exert a force against the friction device,a first spring extending between the drum and the friction plunger andadapted to exert a spring force against the friction plunger, and asecond spring is adapted to exert a spring force against the frictiondevice.

There are other advantages and features of this invention which will bemore readily apparent from the following detailed description of theembodiment of the invention, the drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings that form part of the specification, and inwhich like numerals are employed to designate like parts throughout thesame:

FIG. 1 is a perspective view of a vehicle pedal assembly in accordancewith the present invention;

FIG. 1 a is an enlarged vertical cross-sectional view of thehousing/cover clip securing structure of the vehicle pedal assembly ofFIG. 1);

FIG. 2 is a perspective view of the vehicle pedal assembly of FIG. 1with the housing cover exploded therefrom;

FIG. 3 is a partially broken side elevational view of the vehicle pedalassembly of FIG. 1 without the cover;

FIG. 4 is a partially broken perspective view of the drum of the pedalof the vehicle pedal assembly of FIG. 1;

FIG. 5 is an exploded perspective view of the magnet assembly of thevehicle pedal assembly of FIG. 1;

FIG. 6 is a perspective view of the friction pressure plunger andfriction plate of the hysteresis assembly of the vehicle pedal assemblyof FIG. 1;

FIG. 7 is a vertical cross-sectional view of the vehicle pedal assemblyof FIG. 1 with the pedal in its disengaged idle position;

FIG. 8 is a vertical cross-sectional view of the vehicle pedal assemblyof FIG. 1 with the pedal in its engaged acceleration position;

FIG. 9 is a part phantom, side elevational view of the vehicle pedalassembly of FIG. 1;

FIG. 10 is a front vertical cross-sectional view of the vehicle pedalassembly of FIG. 1 taken along the line 10-10 in FIG. 9;

FIG. 11 is a front vertical cross-sectional view of the vehicle pedalassembly of FIG. 1 taken along the line 11-11 in FIG. 9; and

FIG. 12 is a front vertical cross-sectional view of the vehicle pedalassembly of FIG. 1 taken along the line 12-12 in FIG. 9.

DETAILED DESCRIPTION OF THE EMBODIMENT

The FIGURES depict a vehicle pedal assembly 10 in accordance with thepresent invention which comprises, in part, a pedal housing 20 and apedal 150 extending into the pedal housing 20.

The pedal housing 20, which may be made of any suitable molded plasticmaterial, includes a base wall or floor 22 (FIGS. 1, 2, 3, 7, 8, 9, and12); a pair of spaced-apart and generally parallel side walls 24 and 27(FIGS. 1, 2, 3, 7, 8, 9, 10, 11, and 12) extending generally normallyoutwardly from the floor 22; a partial front wall 21 (FIGS. 1, 2, 3, 7,8, 9, 10, and 11) extending outwardly from the front peripheral edge ofthe base wall 22; a back or rear or top generally arcuate wall 28 (FIGS.1, 2, 3, 7, 8, and 9) extending outwardly from the back or rear or topperipheral edge of the base wall 22 and extending between the respectiveback or rear or top peripheral edges of the respective side walls 24 and27; and a front wall 30 (FIGS. 1, 2, 3, 7, 8, 9, 11, and 12) extendingbetween the front peripheral edge of the respective side walls 24 and 27and the back wall 28 in a relationship spaced and opposed to the basewall 22.

The base wall 22, the side walls 24 and 27, the partial front wall 21,the back or top wall 28, and the front wall 30 together define a fronthousing opening 32 (FIGS. 1, 3, 7, 8, and 11) and an interior housingcavity 34 (FIGS. 2, 3, 7, 8, 9, 10, and 12). The back or top wall 28includes an interior surface 36 (FIGS. 2, 3, 7, and 8) that faces intothe interior housing cavity 34, extends in a relationship generallynormal to the respective side walls 24 and 27, and together with theback or top wall 28 defines a back or top housing opening 29 (FIGS. 2and 3) through which is inserted a combination printed circuit board(PCB) holder/connector 500 as described in more detail below.

The interior of the housing 20 and, more specifically, the interiorsurface of respective ones of the housing walls, includes severalpartial interior walls or ribs protruding generally normally outwardlytherefrom into the interior of the housing cavity 34 as described inmore detail below.

A first partial, and generally L-shaped, wall or rib 42 (FIGS. 2, 3, 7,8, and 9) is located in the housing cavity 34 on a first or front sideof the drum 156 of the pedal 50 and includes a first end defining anelongate extended housing shoulder and pedal arm stop 42 a (FIGS. 1, 2,3, 9, and 11) and a second free end 42 b (FIG. 3) spaced from the firstend, the front wall 30, and the drum 156. The elongate extendedhorizontal shoulder 42 a of the wall 42 defines an extended peripheralhorizontal edge on the front housing wall 30 that is positioned in arelationship opposed and adjacent the exterior surface 191 of the drum156 of the pedal 150. In the embodiment shown, the rib 42 is defined byplastic material protruding outwardly from the front housing wall 30 andthe housing side walls 24 and 27.

Another partial wall or rib 44 (FIGS. 2, 3, 7, and 8), which comprisesplastic material protruding generally normally outwardly from both theinterior surface of each of the housing side walls 24 and 27 and theinterior surface of the housing base wall 22, is located and defined inthe housing cavity 34 below and adjacent the exterior surface 191 of thedrum 156 of the pedal 150 and includes a first end unitary with theinterior surface of the base wall 22 and a second angled free end thatdefines a pedal arm stop and is located adjacent and opposed to theexterior surface 191 of the drum 156 of the pedal 150. The partial wallor rib 44 is located on a second or base side of the drum 156 oppositethe first or front side of the drum 156 with the partial wall or rib 42adjacent thereto.

Yet another partial wall or rib 53 (FIGS. 2, 3, 7, 8, and 9), thatcomprises plastic material protruding outwardly from both the interiorsurface of each of the housing side walls 24 and 27 and the interiorsurface of the housing base wall 22, is located and defined in thehousing cavity 34 on the second or base side of the drum 156 of thepedal 150 and includes a first end unitary with the interior surface ofthe housing base wall 22 and a second end spaced and located below thepartial wall 44 and together with the partial wall 44 define an interiorarcuate receptacle or chamber 55 (FIGS. 2, 3, 7, 8, and 9) that islocated in the interior of the housing 20 below and on the housing basewall side of the drum 156 of the pedal 150 and adjacent the lowerperipheral horizontal edge of the front housing opening 32.

Yet additional spaced-apart and generally parallel partial walls or ribs57 and 59 (FIGS. 2, 3, 7, 8, and 9), which comprise plastic materialprotruding generally normally outwardly from the interior surface ofeach of the housing side walls 24 and 27 and the interior surface of thehousing base wall 22, are located in a relationship spaced and below thepartial wall 53 and together define an interior receptacle 63 (FIGS. 2,3, 7, 8, and 9) for a vehicle pedal kickdown assembly 700 as describedin more detail below.

Yet a further partial wall or rib 60 (FIGS. 3, 7, 8, and 9) is comprisedof plastic material protruding generally normally outwardly from theinterior surface of each of the housing side walls 24 and 27 and theinterior surface of the housing base wall 22 and is located in theinterior of the housing 20 in a relationship adjacent and opposed to theexterior surface 191 of the drum 156 and above the wall or rib 44. Thewall or rib 60 includes a first end unitary with the base wall 22 and asecond free end which is located adjacent and opposed to the exteriorsurface 191 of the drum 156. The partial walls or ribs 44 and 60 arepositioned in a spaced-apart and generally parallel relationship andtogether define an interior receptacle or chamber 93 (FIGS. 3, 7, 8, and12) in the interior of the housing 20. The wall or rib 60 and thereceptacle or chamber 93 are both located on the second or housing basewall side of the drum 156 opposite the first or front side of the drum156 with the partial wall or rib 42 adjacent thereto.

An additional pair of partial, spaced-apart, and generally parallelwalls or ribs 46 and 47 (FIGS. 7 and 8), that are made of plasticmaterial protruding generally normally outwardly from the interiorsurface of the housing side wall 24, are located in an upper or rearcorner of the housing 20 and cavity 34 in a relationship above andspaced from the drum 156 of the pedal 150 and spaced and generallynormal to and in front of the interior surface 36 of the back housingwall 28.

Each of the walls 46 and 47 includes a first shouldered end 48 (FIGS. 7and 8) defining a stop for a friction pressure plunger 684 (FIGS. 3, 6,7, and 8). The wall 46 additionally defines a second end or shoulder oridle stop 49 (FIGS. 7 and 8) that is opposed and spaced from the end 48and defines an idle stop for a pedal lever arm 160 and thus an idle stopfor the pedal 150. The walls 46 and 47 in combination also define anelongate channel 51 (FIGS. 7 and 8) therebetween.

The housing side walls 24 and 27 additionally include respective arcuateand diametrically opposed walls or ribs 101 and 103 (FIGS. 10 and 11) ofplastic material that project outwardly from the interior surface of therespective housing side walls 24 and 27 and define respective extendedand diametrically opposed arcuate housing side wall shoulders in theregion of the front opening 32 of the pedal housing 20.

A plurality of spaced-apart anchors 63 a, 63 b, 63 c, and 63 d (FIGS. 1,2, 3, 7, 8, 9, 10, 11, and 12) extend and project outwardly from thepedal housing 20 and, more specifically, extend and project outwardlyfrom respective ones of the housing walls.

The anchor 63 a (FIGS. 1, 2, 3, 7, 8, 9, 10, and 11) extends andprojects outwardly from a lower front corner of the housing 20 definedby a lower corner of the housing side wall 24 and the housing base wall22.

The anchor 63 c (FIGS. 3, 7, 8, and 9) extends and projects outwardlyfrom an upper back corner of the housing 20 wherein the back or tophousing wall 28 is joined to an upper back corner of the housing basewall 22.

The anchor 63 b (FIGS. 1, 2, 3, 7, 8, 9, 10, 11, and 12) extends andprojects outwardly from the upper front corner of the housing 20 wherethe housing side wall 24, the top or rear housing wall 28, and thehousing front wall 28 are joined together.

The anchor 63 d (FIGS. 3, 7, 8, and 9) is located between the anchors 63a and 63 c and extends and projects outwardly from the exterior surfaceof the housing base wall 22.

As shown in FIG. 2, the anchor 63 a (and, although not described orshown herein in any detail, each of the other anchors 63 b, 63 c, and 63d) defines a generally cylindrically-shaped aperture adapted to receivean anchor insert 67 and defined by an interior surface 69 which includesa plurality of deformable/crushable ribs 75 which allow the respectiveanchor inserts 67 to be press-fitted into the anchor 63 a.

The anchor insert 67 includes a hexagon-shaped head 77, a generallycylindrically-shaped collar 79 extending unitarily outwardly from thehead 77, and a threaded interior through-hole 81 extending through thehead 77 and the collar 79.

The pedal housing 20 is securable to a vehicle using fasteners such asbolts or screws (not shown) that pass through the anchor insert 67 inthe respective anchors and, more specifically, fasteners that arethreaded into and through the through-hole 81 in the insert 67 in therespective anchors and then into respective threaded through-holes (notshown) defined in the firewall (not shown) or the pedal rack (not shown)of the vehicle (not shown). Thus, when the pedal assembly 10 is securedto the vehicle, it is positioned in the vehicle in the generallyvertical orientation as shown in FIG. 3 with the pedal 150 and theanchor 63 a opposite and generally normal to the floor pa (not shown) ofthe vehicle.

In the embodiment shown, the base housing wall 22, the partial fronthousing wall 21, the top or rear or back housing wall 28, and the fronthousing wall 30 are unitary with respective ones of the peripheral edgesof the side housing wall 24 to define a housing member 97 and thehousing side wall 27 is in the form of and defines a separate housingcover which is coupled and secured to the housing member 97 in aspaced-apart relationship.

Thus, in the embodiment as shown in FIGS. 1 a and 2, the housing sidewall or cover 27 includes a plurality of elongate and flexible clip armsor prongs 83 extending around the periphery of the housing side wall orhousing cover 27 in a spaced-apart relationship and, more specifically,in a relationship projecting generally normally outwardly from theperipheral edge of the housing side wall or housing cover 27. Each ofthe clip arms or prongs 83 includes a distal head 85 having a slopedexterior camming surface and defining a clip shoulder 87.

Moreover, in the embodiment as shown in FIGS. 2, 3, 7, and 8, thehousing 20 and, more specifically, the housing base wall 22, the housingside wall 24, the top or rear housing wall 28, and the front housingwall 30 of the housing member 97 thereof, include additional partialwalls or ribs 89 of plastic material that define respective clipreceiving apertures or brackets 91 that extend around the periphery ofthe housing member 97 in a spaced-apart relationship.

As shown in FIG. 1 a, the interior surface of the housing base wall 22,the housing side wall 24, the housing top wall 28, and the housing frontwall 30 in the region of the clip receiving apertures or brackets 91includes a sloped exterior camming segment or portion 93 that defines aclip shoulder 95.

Further, and as shown in FIGS. 1 a and 2, the housing 20 and, morespecifically, the housing base wall 22, the housing top wall 28, and thehousing front wall 30 of the housing member 97 thereof, includerespective guide posts 98 that project outwardly from the proximal edgethereof in a relationship co-linearly aligned with the respective clipreceiving brackets 91 and are adapted to guide and direct the respectivedip arms 83 on the housing cover 27 into the respective apertures orbrackets 91 in the housing member 97.

Still further, the housing member 97 includes at least first and secondguide pins 105 and 107 (FIGS. 2, 3, and 9) protruding generally normallyoutwardly from the interior surface of the housing side wall 24 and thehousing side wall or cover 27 includes a pair of guide pin receivingapertures 109 and 111 (FIGS. 1 and 2) positioned in a diametricallyopposed relationship to the respective guide pins 105 and 107. The guidepins 105 and 107 are located in the interior housing cavity 34 with theguide pin 105 located below the drum 156 of the pedal 150 in arelationship opposed, spaced from, and generally parallel to the housingbase wall 22 and the guide pin 107 located above the drum 156 in arelationship opposed, spaced from, and generally parallel to the housingfront wall 30.

Thus, and referring to FIGS. 1 a and 2, the securement of the housingcover 27 to the housing member 97 includes initially positioning of thehousing cover 27 and the housing member 97 in a generally parallelrelationship opposite each other wherein the respective clip arms 83 onthe housing cover 27 are co-linearly aligned with the respective guideposts 98 and the respective clip receiving brackets 91 on the housingmember 97.

The housing cover 27 and the housing member 97 are then brought togetherin a relationship wherein the respective guide pins 105 and 107 in thehousing member 97 are inserted into the respective guide pin receivingapertures 109 and 111 in the housing cover 27 and the respective cliparms 83 on the housing cover 27 are inserted into the respective clipreceiving brackets 91 in the housing member 97 and extended therethroughinto the clipped position as shown in FIG. 1 a wherein the shoulder 87on the head 85 of the respective clip arms 83 is abutted and wedgedagainst the shoulder 87 defined on the surface of the respective clipreceiving brackets 91 for securing the housing cover 27 to the housingmember 97.

The pedal 150 includes an elongated pedal arm 152 (FIGS. 1, 2, 3, 4, 7,8, 9, 10 and 11) with a pedal pad 153 (FIGS. 1 and 2) at a distal firstend thereof and a generally cylindrical drum 156 (FIGS. 2, 3, 4, 7, 8,9, 10, 11, 12, and 13) at a proximal second end thereof.

The drum 156 of the pedal 150 projects from a distal end of the pedalarm 152 and includes a generally cylindrically-shaped body that includesa plurality of interior body chambers 179 separated by a plurality ofinterior ribs or spokes 181 (FIGS. 2, 3, 4, 10, and 11).

The drum 156, which includes an exterior arcuate surface 191 (FIGS. 2,3, 4, 7, 8, and 12), also defines a generally cylindrically-shapedthrough-hole or aperture 158 (FIGS. 3, 7, and 8) that extends generallycentrally through the body of the drum 156. A generallycylindrically-shaped collar 157 (only one of which is shown in FIGS. 2,3, and 4) projects outwardly from each side of the drum 156. Anelongated hysteresis pedal lever arm 160 (FIGS. 3, 4, 7, 8, 9, and 10)projects unitarily outwardly from a top or back exterior face of thedrum 156.

The distal end and drum 156 of the pedal arm 152 of the pedal 150extends through the front opening 32 of the pedal housing 20 and intothe interior housing cavity 34 and the respective drum collars 157 areseated on respective shoulders (not shown) projecting outwardly from theinterior surface of the respective housing side walls 24 and 27 formounting the drum 156, and thus the pedal 150, to the pedal housing 20for rotation relative to the pedal housing 20.

The drum 156 also includes a pair of generally arcuate and diametricallyopposed peripheral and extended lips or wings or shoulders 157 and 159(FIGS. 2, 3, 4, 9, 10, and 12) projecting outwardly from respectiveopposed peripheral side edges of the exterior arcuate surface 191 of thedrum 156 in the region of the lower or front portion of the drum 156located opposite the housing front opening 32.

As shown in FIG. 10, the drum 156 of the pedal 150 extends and islocated in the housing 20 in a relationship wherein the extendedshoulders 157 and 159 on the drum 156 are positioned opposite, behind,and adjacent the respective extended shoulders 101 and 103 on therespective housing side walls 23 and 27 and further in a relationshipwherein the peripheral distal face of the respective extended drumshoulders 157 and 159 are positioned opposite and adjacent the interiorsurface of the respective housing side walls 24 and 27.

The drum 156 also includes an elongate and generallyrectangularly-shaped tongue or projection or tab 161 (FIGS. 2, 3, 4, 7,8, 9, and 12) which extends and projects outwardly from the exteriorsurface 191 of the drum 156 in a lower front region of the drum 156wherein the lower surface of the pedal arm 152 joins the exteriorsurface 191 of the drum 156. The tab 161 is adapted for movement in theinterior of the receptacle 55 defined in the interior of the housing 20in response to the rotation of the pedal 150.

The drum 156 further includes a pair of additional generallyrectangularly-shaped ears or projections 163 and 165 (FIGS. 2, 3, 4, 7,8, 9, and 12) which extend and project outwardly from the exteriorsurface 191 of the drum 156. Each of the tabs 163 and 165 extends thefull width of the exterior surface 19 the drum 156. The tab 163 includesopposed peripheral shoulders 163 a and 163 b (FIG. 4) extendingoutwardly from the opposed sides of the drum 156. In a like manner, thetab 165 includes opposed peripheral shoulders 165 a and 165 b (FIGS. 4and 10) extending outwardly from the opposed sides of the drum 156.

The ear 163 projects from a lower or front portion of the drum 156 in arelationship adjoining and unitary with a lower edge of the drumshoulders 157 and 159 and is adapted for movement in the interior of thereceptacle 93 defined in the housing 20 in response to the rotation ofthe pedal 150.

The ear 165 is located on an upper or back portion of the drum 156, andon a side of the drum 156 opposite the side of the drum 156 with the ear163, in a relationship adjoining and unitary with an upper edge of thedrum shoulders 157 and 159 and further in a relationship wherein adistal tip of the ear 165 is positioned opposite and adjacent theinterior surface of the free end 42 b of the partial interior housingwall or rib 42 to define a chamber 77 (FIGS. 3, 7, 8, and 9). The ear165 is also adapted for movement relative to the partial wall or rib 42in response to the rotation of the pedal 150.

In accordance with the present invention and as described in more detailbelow, the lower tab 161 on the drum 156 and the upper housing wallshoulder 42 a define respective first barriers that block the entry ofdebris through the respective lower and upper portions of the fronthousing opening 32; the respective extended drum shoulders 157 and 159in combination with the respective housing wall shoulders 101 and 103define respective first barriers that block the entry of debris throughthe respective side portions of the front housing opening 32; the ears163 and 165 on the drum 156 and the interior lower housing ribs 44 and60 define secondary barriers in the interior of the housing 20 thatblock the entry of debris into the upper portion of the interior cavity34 that houses the hysteresis assembly 600; and the interior housingchambers 77 and 93 and the interior drum chambers 179 define debrisretention or settling regions or chambers as also described in moredetail below.

Particularly, and because air blown from the vehicle floor pan (notshown) is strongest on the underside of the pedal arm 152 in theorientation of the pedal assembly 10 in a vehicle as shown in FIG. 2,the tab 161 on the drum 156 acts as an initial or first barrier orshield or stop that blocks debris from entering upwardly from thevehicle floor pan into the interior of the pedal assembly 10 via andthrough the lower portion of the housing opening 32 located below thepedal 150 and the drum 156.

The positioning of the housing rib 42 in a relationship wherein aperipheral portion thereof is positioned opposite and adjacent theexterior surface 191 of the drum 156 creates another initial or firstbarrier or shield or stop that blocks debris from entering upwardly fromthe vehicle floor pan into the interior of the pedal assembly 10 via andthrough the top front portion of the housing opening 32 located abovethe pedal 150 and the drum 156.

Further, the extended shoulders 101 and 103 on the respective housingside walls 24 and 27 and the extended shoulders 157 and 159 on theexterior surface 191 of the drum 156 together reduce the size of the gapin the region of the opposed sides of the housing front opening 32 andtogether define an additional first or initial barrier or shield or stopthat blocks the entry of debris upwardly from the floor pan into theinterior cavity 24 of the housing 20 of the pedal assembly 10 via andthrough the opposed sides of the housing front opening 32.

A secondary debris barrier or shield or stop is defined by the partialhousing wall or rib 44 located behind and above the drum tab 161 and, asdescribed above, is positioned in a relationship adjacent the exteriorsurface 191 of the drum 156 and blocks any debris which enters throughthe housing opening 32 from moving or traveling further upwardly intothe interior cavity 34 of the housing 20.

The drum ears 163 and 165 act as additional secondary debris barriers orshields or stops that block any debris which passes through the debrisbarriers described above from moving further upwardly into the portionof the interior cavity 34 of the housing 20 containing the idle stop 46and the hysteresis assembly 600 as described in more detail below.

More specifically, the distal tip of the ear 165 on the drum 156 ispositioned in a relationship opposite and adjacent the interior surfaceof the free end 42 b of the partial housing wall 42; the distal end faceof the respective shoulders 165 a and 165 b of the ear 165 arepositioned in a relationship opposite and adjacent the interior surfaceof the respective housing side walls 24 and 27; the distal tip of thepartial housing wall 60 is positioned in a relationship opposite andadjacent the exterior surface 191 of the drum 156; the ear 163 isadapted to abut against the side surface of the partial housing wall 44in response to rotation of the pedal 150; and the distal end faces ofthe respective shoulders 163 a and 163 b of the ear 163 are positionedin a relationship opposite and adjacent the interior surface of therespective housing side walls 24 and 27 to define additional second orsecondary debris barriers or shields or stops that block debris frommoving further upwardly into the portion of the interior cavity 24 ofthe housing 20 containing the idle stop 46 and the hysteresis assembly600.

Still further, the region or space between each of the exterior sidefaces of the drum 156 and the interior surface of the respective housingside walls 24 and 27 in the horizontal direction and between the drumshoulders 157 and 159 and the drum ear shoulders 163 b and 165 b in thevertical direction define respective interior housing chambers 167 a and167 b (FIG. 12) on opposed sides of the drum 156 in which the airvelocity will be very low (by virtue of the fact that the majority ofthe air has been blocked by the initial debris barriers described aboveand more specifically by the extended drum shoulders 157 and 159) andthus define regions in which gravity can force debris to settle andcollect in the respective chambers 77, 93, and/or 179.

Still further, and as a result of the incorporation of successivebarriers or shields in the pedal assembly 10 as described above, theupper portion or region of the housing cavity 34 containing the idlestop 46 and the hysteresis assembly 600 is a portion or region orchamber of the housing 20 containing only low velocity air and anydebris in this portion or region or chamber would be required to workagainst the forces of gravity to reach any portion of the idle stop 46or the hysteresis assembly 600 which are both positioned and locatedadjacent the top or back housing wall 28 of the housing 20.

Referring back to FIGS. 2, 3, and 4, the drum 156 of the pedal 150further includes a magnet assembly bracket 171 (FIGS. 3 and 4) thatprojects outwardly from a back or top face of the drum 156 and isdefined by a pair of generally L-shaped spaced-apart hooks or fingers171 a and 171 b (FIG. 4) that protrude outwardly from a back or topportion of the exterior surface of the drum 156 in a diametricallyopposed relationship and together define an interior recess or pocket173 (FIGS. 3 and 4) in the drum 156. The interior face of each of thefingers 171 a and 171 b includes a crushable rib (not shown) projectingoutwardly therefrom in the direction of the exterior surface of the drum156.

As shown in FIGS. 3, 4, 7, 8, and 9, the pedal 150 also includes a pedallever arm 160 which projects from a back or top portion of the exteriorsurface of the drum 156 and extends upwardly and rearwardly through theinterior housing cavity 34 in a relationship between and spaced from thetwo spaced-apart housing side walls 24 and 27 and terminating in adistal tip 164 (FIGS. 7, 8, and 9) that is positioned in a relationshipbelow and spaced from the interior surface 36 of the top or back housingwall 28.

In the idle/disengaged position of the pedal 150 as shown in FIG. 7, afirst exterior side face of the distal tip 164 of the pedal lever arm160 is positioned in abutting relationship with the side surface or faceof the idle stop 46 and, more specifically, in an abutting relationshipwith the side surface or face of the shouldered end 49 of the partialwall 46 in the housing 20.

Referring to FIGS. 3, 4, 7 and 8, the back or top of the pedal drum 56further includes a recess or shoulder 70 that defines a base for thecoil spring 680 of the hysteresis assembly 600 as described in moredetail below. The shoulder 70 is located on a lower or back or top sideof the drum 56 located opposite the housing base wall 22.

The pedal assembly 10 additionally comprises a sensor assembly definedby the combination of a magnet assembly 200 (FIGS. 2, 3, 4, 5, and 10)and a magnetic field sensor 300 (FIG. 10), both located in the portionof housing cavity 34 between the back or rear of the drum 156 and thetop or rear wall 28 of the housing 20.

Further details of the use and construction of the magnet assembly 200can be found in U.S. Pat. No. 6,211,668 entitled “Magnetic PositionSensor Having Opposed Tapered Magnets”, the contents of which are hereinincorporated by reference in their entirety.

In the embodiment of the magnet assembly 200 as shown in FIGS. 2, 3, 4,5, and 10, the magnet assembly 200 comprises a pair of spaced-apart andgenerally parallel magnet plates 202 and 204 (FIGS. 4 and 5) which areeach formed of bonded ferrite or other suitable magnetic material, andare coupled together to a base 206 (FIGS. 4 and 5).

As described in more detail in U.S. Pat. No. 6,211,668 and incorporatedherein by reference, each of the magnet plates 202 and 204 is, in theembodiment shown, tapered in a manner wherein the thickness of therespective plates 202 and 204 at each of the respective end portionsthereof is greater than the thickness of the respective plates 202 and204 at each of the respective center/middle portions thereof and furtherin a manner wherein the thickness of the respective plates 202 and 204increases gradually between the respective center/middle portionsthereof and the respective end portions thereof. An elongate interiorgap or space 205 (FIGS. 4 and 5) is defined between the two magnetplates 202 and 204.

The base 206 of the magnet assembly 200 includes a pair of co-linearlyaligned and elongate recesses or grooves 210 and 212 (FIGS. 4 and 5)defined in the opposed transverse sides of the base 206 and a secondpair of recesses or grooves 214 and 216 (FIG. 5) defined in the opposedlongitudinal sides of the base 206.

The magnet assembly 200 also comprises a pair of metal magnet poleplates 218 and 220 (FIGS. 3, 4, and 5), each of which is generallyfan-shaped and matches the shape of the magnet plates 202 and 204, andincludes an inwardly bent base tab 217 (FIGS. 4 and 5). The magnet poleplate 218 is seated over the exterior surface of the magnet plate 202with the tab 217 thereof seated in the groove 214 defined in the base206 of the magnet assembly 200. In a like manner, the magnet pole plate220 is seated over the exterior surface of the magnet plate 204 with thetab 217 thereof seated in the groove 216 defined in the base 206 of themagnet assembly 200.

The magnet assembly 200 in turn is slid onto and coupled to the bracket171 on the back or top of the drum 156 in a relationship wherein therespective fingers 171 b and 171 a of the bracket 171 extend into therespective grooves 210 and 212 defined in the base 206 of the magnetassembly 200. The ribs (not shown) on the fingers 171 a and 171 b aredeformed/crushed upon clipping of the magnet assembly 200 to the drumbracket 171 to provide a press-fit of the magnet assembly 200 to thepedal drum 156.

The magnetic field sensor 300 (FIG. 10) is positioned in the space orgap 205 of the magnet assembly 200 in a relationship spaced, opposed,and generally parallel to the magnet plates 202 and 204.

As described in more detail in U.S. Pat. No. 6,211,668 and incorporatedherein by reference, the magnet assembly 200 is adapted to create avariable magnetic field that is detected by the magnetic field sensor300 which, in the embodiment shown, is a Hall effect sensor. The magnetassembly 200 and the sensor 300 provide an electrical signal that isrepresentative of the rotational position or displacement of the pedal150 relative to the housing 20. In one embodiment, the magnetic fieldsensor 300 may be a single Hall effect component or device. In theembodiment shown, the magnetic field sensor 300 is an integrated circuitcommercially available from Melexis Corporation of leper, Belgium.

Hall effect sensor 300 is responsive to flux changes induced by thepedal displacement as shown in FIGS. 7 and 8 and the correspondingdisplacement of the magnet assembly 200. Electrical signals from thesensor 300 have the effect of converting the displacement of the pedal150, as indicated by the displacement of the magnet assembly 200, into adictated speed/acceleration command which is communicated to anelectronic control module such as is shown and described in U.S. Pat.Nos. 5,524,589 to Kikkawa et al. and 6,073,610 to Matsumoto et al., thedisclosures of which are hereby expressly incorporated herein byreference.

In the embodiment as shown in FIG. 10, the Hall effect sensor 300 ismounted, as by soldering or the like, to one of the side surfaces of agenerally planar printed circuit board 400 (FIGS. 2 and 10).

Other electronic components (not shown) including, for example,amplifiers and filters, can also be mounted to one or both of the sidesurfaces of the printed circuit board 400 to allow the processing of thesignals generated by the Hall effect sensor 300.

The printed circuit board 400 in turn is mounted to a combinationprinted circuit board holder/connector assembly 500 (FIGS. 2 and 10)which includes a generally rectangularly-shaped holder/frame 502 (FIGS.2 and 10) for the printed circuit board 400 and a connector housing 504(FIGS. 2 and 10) unitary with the printed circuit board holder/framemember 502.

The connector assembly 500 is coupled to the housing 20 in arelationship wherein the frame 502 thereof is located in the housingcavity 34 and at least a portion of the frame 502 containing the sensor300 extends into the space or gap 205 defined between the magnet plates202 and 204 of the magnet assembly 200; and the connector housing 504extends through the opening 29 defined in the top or back housing wall28.

Terminals (not shown) extend from the printed circuit board 400 into theinterior of the connector housing 504 which, in turn, are adapted to bemated to an electrical wiring harness (not shown) that includes aconnector adapted to be fitted within the interior of the connectorhousing 504 and which, in turn, is adapted to be connected to an enginecontroller or computer in the vehicle.

The pedal assembly 10 still further comprises a hysteresis assembly 600(FIGS. 3, 7, and 8) which is comprised of the following separateelements which are all separate and decoupled from each other and thepedal 150: first and second springs 680 and 682 (FIGS. 3, 7, and 8), afriction pressure plunger 684 (FIGS. 3, 6, 7, and 8), a frictionpressure plate 685 (FIGS. 3, 7, and 8), and a friction-generating deviceor sled 686 (FIGS. 3, 6, 7, and 8), all located in the interior housingcavity 34 between the drum 156 and the back or top housing wall 28.

In the embodiment shown, the friction sled 686 and the second spring 682of the hysteresis assembly 600 are positioned in an angled relationship(approximately between 90 to 100 degrees) relative to the frictionplunger 684 and the first spring 680 of the hysteresis assembly 600 withthe friction sled 685 and the second spring 682 of the hysteresisassembly 600 both located in the interior cavity 34 of the housing 20between the drum 156/magnet assembly 200 and the back or rear or topwall 28 of the housing 20 and with the friction pressure plunger 684 andthe first spring 680 both located in the interior cavity 34 of thehousing 20 between the drum 156/magnet assembly 200 and the base wall 22of the housing 20.

The friction pressure plate 685 is seated in a recess or groove 97 (FIG.3, 7, and 8) defined in the interior surface 36 of the top or backhousing wall 28 in a region of the top or back housing wall 28 locatedopposite the partial walls 46 and 47 defined in the interior of thehousing 20.

The friction sled 686, which is decoupled and separate from the pedal150, includes a generally elongate and arcuate base 688 (FIGS. 3, 6, 7,and 8) that includes an interior surface abutted against the frictionpressure plate 685 and an exterior surface abutted against the interiorsurface 36 of the top or back housing wall 28 and is located in theinterior housing cavity 34 of the housing 20 in the space thereoflocated and defined between the partial walls 46 and 47 and the top orback housing wall 28.

The friction sled 686 is positioned in the housing cavity 34 in arelationship opposite and adjacent the interior surface 36 of the backor top housing wall 28 and further in a relationship generally normal tothe housing base wall 22.

The friction sled 686 also includes a lip 690 (FIGS. 3, 6, 7, and 8)that extends generally normally outwardly from the end of the base 688and includes an exterior spring base or collar 689 (FIGS. 3, 6, 7, and8) formed on an exterior surface thereof.

As shown in FIG. 7, in the idle/disengaged position of the pedal 150,the distal tip 164 of the drum lever arm 160 extends and is locatedinside the friction sled 686 in a relationship sandwiched between theinterior surface of the lip 690 of the friction sled 686 and theexterior surface of the second end 49 of the idle stop wall 46 and, morespecifically, is positioned therebetween in a relationship wherein afirst side face of the distal tip 164 is in abutting relationship withthe interior surface of the friction sled lip 690 and the second opposedside face of the distal tip 164 is in abutting relationship with theexterior side surface of the end 49 of the idle stop wall 46.

As still further shown in FIGS. 6, 7, and 8, the friction pressureplunger 684 is generally I-shaped in vertical cross-section and iscomprised of a generally elongate central base plate 692 and two endplunger plates 694 and 696. The plunger plate 694 projects generallynormally and unitarily outwardly from one end of the base 692 while theplunger plate 696 projects generally angularly and unitarily outwardlyfrom the opposite end of the base 692.

The friction pressure plunger 684 is located and positioned in theinterior housing cavity 34 of the pedal housing 20 in an angledrelationship (approximately between 90 to 100 degrees) relative to thefriction sled 686 in which the elongate central base 692 thereof isseated in and extends through the channel 51 defined by and between thepartial interior housing walls or ribs 46 and 47; the plate 694 islocated below and generally parallel to the lower ends or shoulders 48of the partial interior housing walls or ribs 46 and 47 and the plate696 is located between the upper ends of the partial interior housingwalls or ribs 46 and 47 and the base 688 of the friction sled 686 in arelationship wherein the outer surface of the plunger plate 696 isabutted against the outer surface of the base 688 of the friction sled686.

The first spring 680 which, in the embodiment shown is of the helicalcoil type, extends between the drum shoulder 70 and the frictionpressure plunger 684 in a generally co-linear relationship relative tothe friction pressure plunger 684 and in an angled relationship(approximately between 90 to 100 degrees) relative to the friction sled686 and, more specifically and as shown in FIGS. 3, 7, and 8, includes afirst lower end abutted against, and surrounding the spring collar 71(FIGS. 3, 7, and 8) on, the drum shoulder 70 and an opposed second upperend abutted against, and surrounding the spring collar 687 (FIGS. 3, 7,and 8) on, the outer surface of the lower plunger plate 694 of thefriction pressure plunger 684.

The second spring 682 is also of the helical coil type and is positionedin the interior housing cavity 34 in an angled (approximately between 90to 100 degrees) relationship relative to the friction pressure plunger684 and the first spring 680, in a relationship generally co-linear withand in the same direction as the friction sled 686, and in arelationship generally parallel to and adjacent the interior surface 36of the back or top housing wall 28. The second spring 682 extendsbetween the spring base defined by the interior surface of the fronthousing wall 30 and the friction sled 686 and, more specifically and asalso shown in FIGS. 3, 7, and 8, includes a first end abutted againstthe interior surface of the housing wall 30 and an opposed second endabutted against, and surrounding the spring collar 689 (FIGS. 3, 7, and8), on the exterior surface of the lip 690 of the friction sled 686.

In the embodiment as shown in FIGS. 7 and 8, the pedal 150 is rotatablerelative to the pedal housing 20 in a counter-clockwise direction inresponse to the application of a step force against the pedal pad 153(FIGS. 1 and 2) by the foot (not shown) of the vehicle operator (notshown).

The counter-clockwise rotation of the pedal 150 from its idle or rest ordisengaged position as shown in FIGS. 3 and 7 where the distal tip 164of the pedal lever arm 160 is abutted against the idle stop 46 into theengaged or acceleration position shown in FIG. 8 where the accelerationpedal stop 162 on the underside of the pedal arm 152 is abutted againstthe pedal stop surface 92 on the front wall 30 of the housing 20 causesthe counter-clockwise rotation of the drum 156 which causes thecompression of the first spring 680 which causes the distal end of thefirst spring 680 to move and exert a compressive spring force againstthe plate 694 of the friction pressure plunger 684 which, in turn, istransmitted through the base 692 of the plunger 684 to the upper plate696 of the plunger 684 to exert a compressive force against the base 688of the friction sled 686 which, in turn, causes or presses or pushes thebase 688 of the friction sled 686 upwardly or rearwardly in the housingcavity 34 into abutting frictional contact with the friction pressureplate 685 located in the interior surface 36 of the back housing wall 28which, in turn, causes the generation and transfer of a first frictionalresistance pedal arm hysteresis force to the pedal 150 of the typedisclosed in, for example, U.S. Pat. No. 7,404,342, the description ofwhich is incorporated herein by reference for the purpose of emulatingthe feel and tactile response of a cable-driven pedal assembly in acable-less, non-contacting sensor-based pedal assembly of the presentinvention.

As further shown in FIG. 8, the counter-clockwise rotation of the pedal150 also simultaneously causes the counter-clockwise movement androtation of the pedal lever arm 160 in the interior housing cavity 34 inthe direction of and towards the housing front wall 30 (away from theidle stop 46) which, as a result of the placement of the distal tip 164of the pedal lever arm 160 in the interior of the friction sled 686 andin an abutting relationship with the lip 690 of the friction sled 686,causes the counter-clockwise movement of the friction sled 686 along andagainst the interior surface 36 of the back or top housing wall 28 awayfrom the housing base wall 22 and towards the housing front wall 30which, in turn, causes the compression of the second spring 682 seatedagainst the exterior surface of the lip 690 of the friction sled 686.

In accordance with the invention, the level or magnitude of thefrictional resistance hysteresis force generated and transferred to thepedal 150 by the hysteresis assembly 600 will be dependent upon and maybe adjusted or changed by adjusting or changing a variety of parametersincluding, but not limited to, the following: the material and/or springforce characteristics of the coil springs 680 and 682; the material orprofile or configuration or location of the friction plunger 684 and thefriction sled 686; the material profile or configuration of the frictionplate 685; and the profile or configuration or location of the pedallever arm 160 and drum shoulder 70.

Further, and as shown in FIGS. 1, 2, 3, 7, and 8, the pedal assembly 10also comprises a pedal kickdown assembly 700 of the type disclosed inU.S. Patent Application Publication No. US 2009/0173587 published onJul. 9, 2009, the disclosure of which is also incorporated herein byreference.

The pedal kickdown assembly 700, which includes a plunger 702 (FIGS. 1,2, 3, 7, and 8), is mounted in the housing 20 and, more specifically, ismounted in the receptacle 63 defined in the housing 20 in a relationshipgenerally normal to the housing base wall 22 herein the plunger 702protrudes outwardly from the base 22 of the housing 20 and is positionedopposite and spaced from the lower interior surface of the pedal arm 152in the idle position of the pedal 150 as shown in FIGS. 1, 2, 3, and 7.

The pedal kickdown assembly 700, which is located outside of the housingcavity 34 and below the drum 156 and which extends and is positioned inan orientation and direction generally opposite and under the pedal arm152, is activated when the pedal 150 is rotated counter-clockwise fromits position in FIGS. 1, 2, 3, and 7 into its position as shown in FIG.8 wherein the underside or interior surface of the pedal arm 152 isbrought into abutting relationship with the top of the plunger 702which, initially, generates an opposing mechanical resistance force onthe pedal and provides a tactile feedback to the foot of the operatorfollowed by depression of the plunger 702 in response to the furtherdepression and rotation of the pedal 150.

Although not described in any detail herein, it is understood thatremoval by the operator of his/her foot from the pedal 150 causes thefirst spring 680 to expand which causes the proximal end of the firstspring 680 to move and exert a compressive force against the drumshoulder 70 which causes the clockwise rotation of the drum 156 and drumshoulder 70 which, in turn, reduces the pressure or force applied by thefirst spring 680 on the plunger 684 which, in turn, reduces thefrictional contact between the friction sled 686 and the friction plate685 and rotates and returns the pedal 150 to its idle position of FIG. 7in which the pedal lever arm 160 is abutted against the idle stop 46.Removal of an operator's foot from the pedal 150 also moves the pedalaway from the plunger 702 of the pedal kickdown assembly 700 todeactivate the kickdown assembly 700.

It is further understood that removal by the operator of his/her footfrom the pedal 150 also relieves the pressure or force applied to thesecond spring 682 by the pedal lever arm 160 which, in turn, allows theexpansion of the second spring 682 which, in turn, allows the distal endof the second spring 682 to move and exert a compressive spring forceagainst the lip 690 of the friction sled 686 which simultaneously pushesthe friction sled 686 along and against the friction plate 685 in asecond clockwise direction back towards the housing base wall 22 that isopposite the first counter-clockwise direction away from the housingbase wall 22 which the lever arm 160 moves the friction sled 686 whenthe pedal 150 is rotated counter-clockwise and additionally also pushesthe pedal arm lever 160 and the pedal 150 back clockwise in thedirection of the housing base wall 22 back into its idle/disengaged/restposition and configuration as shown in FIG. 7.

It is still further understood that the vehicle pedal assembly 10 andthe hysteresis assembly 600, and more specifically the first and secondsprings 680 and 682, the friction pressure plunger 684, the frictionpressure plate 685, the friction sled 686, and the pedal lever arm 160define means structured and operated in a manner that allow the pedal150 to rotate from its acceleration/depressed position or condition ofFIG. 8 and return back into its idle/disengaged position of FIG. 7immediately upon removal of the operator's foot and corresponding footforce from the pedal 150 independent of the operability and with andwithout the movement of the first or second springs 680 and 682, thefriction plunger 684, or the friction plate 685 as described above andin more detail below.

Specifically, if the second spring 682 becomes inoperable for any reasonwhile the pedal 150 is in the acceleration/depressed position orcondition of FIG. 8, as for example where the second spring 682 isunable to expand and thus unable to move and exert the compressivespring force against the lip 690 of the friction sled 686 and thusunable to move the friction sled 686 and thus the pedal level arm 160clockwise to return the pedal 150 to its idle position, the removal ofthe operator's foot and corresponding foot force from the pedal 150 willcause an expansion of the first spring 680 which, in turn, will causethe proximal end of the first spring 680 to exert a compressive forceagainst the shoulder 70 of the drum 156 of the pedal 150 which, in turn,will cause the clockwise rotation of the drum 156 and thus the clockwiserotation and return of the pedal 150 back into its idle/disengagedposition of FIG. 7.

Thus, the use of hysteresis assembly elements which are separate anddecoupled from each other and the pedal 150 as described above andfurther the use of a hysteresis assembly 600 that includes a firstspring 680 that is separate and operates independently of the secondspring 682 provides and allows for the rotation and return of the pedal150 to its idle position without the compressive spring force of thesecond spring 682 against the friction sled 686.

Additionally, if the friction sled 686 becomes inoperable or unable tomove for any reason while the pedal 150 is in the acceleration/depressedposition or condition of FIG. 8, the removal of the operator's foot andcorresponding foot force from the pedal 150 will cause an expansion ofthe first spring 680 which, in turn, will cause the proximal end of thefirst spring 680 to exert a compressive spring force against theshoulder 70 of the drum 156 which, in turn, will cause the clockwiserotation of the drum 156 and thus the clockwise rotation and return ofthe pedal 150 back into its idle/disengaged position of FIG. 7.

Thus, the use of hysteresis assembly elements which are separate anddecoupled from each other and the pedal 150 as discussed above andfurther the use of a hysteresis assembly 600 including a friction sled686 and a first spring 680 that are decoupled and separate from eachother and the pedal 150 allows the first spring 680 to rotate and returnthe pedal 150 back into its idle/disengaged position of FIG. 7 both withand without the operability or movement of the friction sled 686 asdescribed above.

Further, if the first spring 680 becomes inoperable for any reason whilethe pedal 150 is in the acceleration/depressed position or condition ofFIG. 8, as for example where the first spring 680 is unable to expandand thus unable to move and exert the compressive spring force againstthe shoulder 70 of the drum 156 of the pedal 150 to cause the clockwiserotation of the pedal 150 back into its idle position as describedabove, the pressure or compressive spring force applied by the distalend of the spring 680 on the friction pressure plunger 684 will bereduced which, in turn, will reduce the frictional contact between thefriction sled 686 and the friction plate 685 which, upon removal of theoperator's foot and corresponding foot force from the pedal 150 willcause the expansion of the second spring 682 which will cause the distalend of the second spring 682 to move and exert a compressive springforce against the lip 690 of the friction sled 686 which will cause theclockwise movement of the friction sled 686 which, in turn, will causethe clockwise movement of the pedal lever drum 160 that is abuttedagainst the interior surface of the lip 690 of the friction sled 686which, in turn, will cause the clockwise rotation of the drum 156 andthus the clockwise rotation and return of the pedal 150 back into itsidle/disengaged position of FIG. 7.

Thus, the use of hysteresis assembly elements as described above whichare separate and decoupled from each other and the pedal 150 asdescribed above and further the use of a vehicle pedal assembly 10 andhysteresis assembly 600 that includes a pedal lever arm 160, a frictionsled 686, and a second spring 682 that is separate from and operatesindependently of the first spring 680 provides and allows for therotation and return of the pedal 150 to its idle position without thecompressive spring force of the first spring 680 against the pedal 150.

Still further, if the friction pressure plunger 684 becomes inoperableor unable to move for any reason while the pedal 150 is in theacceleration/depressed position or condition of FIG. 8, the removal ofthe operator's foot and corresponding foot force from the pedal 150 willcause an expansion of the first spring 680 which, in turn, will causethe proximal end of the first spring 680 to exert a compressive forceagainst the shoulder 70 of the drum 156 which, in turn, will cause theclockwise rotation of the drum 156 and thus the clockwise rotation andreturn of the pedal 150 back into its idle/disengaged position of FIG.7.

Thus, the use of hysteresis assembly elements which are separate anddecoupled from each other and the pedal 150 as discussed above andfurther the use of a friction pressure plunger 684 that is separate anddecoupled from the pedal 150, the friction sled 686, and the firstspring 680 allows the first spring 680 to rotate and return the pedal150 back into its idle/disengaged position of FIG. 7 both with andwithout the operability and movement of the friction pressure plunger684 as described above.

Numerous variations and modifications of the pedal assembly 10 describedabove may be effected without departing from the spirit and scope of thenovel features of the invention. It is thus understood that nolimitations with respect to the vehicle pedal assembly and hysteresisassembly illustrated herein are intended or should be inferred. It is,of course, intended to cover by the appended claims all suchmodifications as fall within the scope of the claims.

1. A vehicle pedal assembly comprising: a pedal housing; a pedalextending into the pedal housing, the pedal being mounted to the pedalhousing for rotation relative to the pedal housing; and a pedalhysteresis assembly in the pedal housing including: a friction deviceadapted for movement in the pedal housing; a friction plunger adapted toexert a force against the friction device; a first spring extendingbetween the pedal and the friction plunger and adapted to exert a springforce against the friction plunger which causes the friction plunger toexert the force against the friction device which causes the frictiondevice into abutting frictional contact with the pedal housing inresponse to the rotation of the pedal to generate and transfer aresistance force to the pedal; a lever arm extending from the pedal intocontact with the friction device and adapted to move the friction devicein a first direction in response to the rotation of the pedal; and asecond spring in contact with the friction device and adapted to exert aspring force against and move the friction device in a second directionopposite the first direction.
 2. The vehicle pedal assembly of claim 1wherein the pedal housing defines a channel and the friction plunger isadapted to move in the channel.
 3. The vehicle pedal assembly of claim 2wherein the friction plunger includes an elongate base extending in thechannel and opposed plunger plates adapted to abut against the firstspring and the friction device respectively.
 4. The vehicle pedalassembly of claim 1 wherein the friction device includes a base abuttedagainst an interior surface of the pedal housing and a wall, the secondspring and the lever arm abutting against the wall of the frictiondevice.
 5. The vehicle pedal assembly of claim 4 wherein the wall of thefriction device extends between the second spring and the lever arm. 6.The vehicle pedal assembly of claim 1 wherein the first end of the pedalincludes a drum defining a shoulder, the first spring extending betweenthe shoulder on the drum and the friction plunger.
 7. The vehicle pedalassembly of claim 1 wherein the pedal housing defines a front openingand includes a back wall, the pedal extending through the front opening,and the friction device being adapted for frictional contact with theback wall of the housing.
 8. A vehicle pedal assembly comprising: apedal housing; a pedal extending into the pedal housing and adapted forrotation relative to the pedal housing from an idle position in responseto the application of a foot force against the pedal; and a pedalhysteresis assembly in the pedal housing including a friction devicethat is separate from the pedal and adapted for movement in the pedalhousing in response to the rotation of the pedal from the idle position;and means for rotating and returning the pedal to its idle position withand without the movement of the friction device.
 9. The vehicle pedalassembly of claim 8 wherein the means for rotating and returning thepedal to its idle position with and without the movement of the frictiondevice comprises a first spring between and separate from the pedal andthe friction device, the first spring generating a first compressiveforce that causes the friction device into abutting frictional contactwith the pedal housing in response to the rotation of the pedal forgenerating and transferring a resistance force to the pedal, the firstspring also being adapted to exert a second compressive force againstthe pedal in response to the removal of the foot force from the pedalthat returns the pedal to its idle position with and without themovement of the friction device.
 10. The vehicle pedal assembly of claim9 wherein the pedal hysteresis assembly includes a friction plunger thatis separate from and extends between the first spring and the frictiondevice, the first spring being adapted to exert the first springcompression force against the friction plunger which causes the frictiondevice into abutting frictional contact with the pedal housing.
 11. Thevehicle pedal assembly of claim 9 wherein the pedal hysteresis assemblyfurther includes means for rotating and returning the pedal to its idleposition without the second compressive force of the first spring. 12.The vehicle pedal assembly of claim 11 wherein the means for rotatingand returning the pedal to its idle position without the secondcompressive force of the first spring comprises a lever arm extendingfrom the pedal into contact with the friction device and a second springextending between the pedal housing and the friction device, the secondspring being adapted to exert a compressive spring force against thefriction device in response to the removal of the foot force from thepedal which causes the movement of the friction device, the rotation ofthe pedal lever arm, and the return of the pedal to its idle positionwithout the second compressive force of the first spring.
 13. Thevehicle pedal assembly of claim 12 wherein the first spring is adaptedto rotate and return the pedal to its idle position without thecompressive spring force of the second spring.
 14. A vehicle pedalassembly comprising: a pedal housing; a pedal extending into the pedalhousing, the pedal being mounted to the pedal housing for rotationrelative to the pedal housing from an idle position in response to theapplication of a foot force against the pedal; and a pedal hysteresisassembly in the pedal housing including: a friction device that isseparate from the pedal and adapted for movement in the pedal housing; afriction plunger that is separate from the friction device and the pedaland adapted to exert a force against the friction device; a first springthat is separate from the pedal and the friction device and the frictionplunger and extends between the pedal and the friction plunger and isadapted to exert a first spring force against the friction plunger whichcauses the friction plunger to exert the force against the frictiondevice which causes the friction device into abutting frictional contactwith the pedal housing in response to the rotation of the pedal togenerate and transfer a resistance force to the pedal, the first springalso being adapted to exert a second spring force against the pedal inresponse to the removal of the foot force from the pedal that returnsthe pedal to its idle position with and without the movement of thefriction device; a lever arm extending from the pedal into contact withthe friction device and adapted to move the friction device in a firstdirection in response to the rotation of the pedal; and a second springin contact with the friction device and adapted to exert a spring forceagainst and move the friction device and the lever arm in response tothe removal of the foot force from the pedal that returns the pedal toits idle position without the second spring force of the first spring,the first spring further being adapted to exert the second spring forceagainst the pedal in response to the removal of the foot force from thepedal to return the pedal to its idle position without the spring forceof the second spring.
 15. A vehicle pedal assembly comprising: a pedalhousing defining a front opening and an interior cavity; a pedalincluding a pedal arm extending through the front opening and a drumlocated in the interior cavity; and a first debris barrier defined atthe front opening of the pedal housing.
 16. The vehicle pedal assemblyof claim 15 wherein the first debris barrier includes respective opposedand adjacent extended shoulders formed on the pedal housing and thepedal drum.
 17. The vehicle pedal assembly of claim 15 furthercomprising another first debris barrier defined by an outwardlyprojecting tab on a lower portion of the drum and located opposite thefront opening of the pedal housing.
 18. The vehicle pedal assembly ofclaim 15 further comprising a second debris barrier defined by at leasta first outwardly projecting ear formed on the drum of the pedal andlocated behind the first debris barrier.
 19. The vehicle pedal assemblyof claim 18 further comprising at least a first debris retention chamberdefined in the interior cavity of the pedal housing between the firstand second debris barriers.
 20. The vehicle pedal assembly of claim 15wherein the pedal housing includes a back wall and further comprising apedal hysteresis assembly located in the interior cavity of the pedalhousing between the drum and the back wall of the pedal housing, thepedal hysteresis assembly including a friction device adapted forsliding movement against the back wall of the pedal housing, a frictionplunger adapted to exert a force against the friction device, a firstspring extending between the drum and the friction plate and adapted toexert a spring force against the friction plunger, and a second springadapted to exert a spring force against the friction device.